6. HOT-WATER HEATING DISTRIBUTION SYSTEMS
Learning Objective: Identify types of hot-water distribution systems and components. Understand the operation and maintenance of these systems.
In hot-water heating systems, the water is heated at a central source and circulated through pipes to radiators, convectors, or unit heaters. There are two general types of low-temperature, hot-water heating systems. The first type is a gravity system in which water circulation depends upon the weight difference between the hot column of water leading to the radiators and the relatively cooler, heavier column of water returning from the radiators. The second type is the forced-circulation system in which water is circulated by a power-driven pump.
The distribution systems and piping for hot-water heating systems and for domestic hot-water supply systems are simpler in design than those for steam because there are no traps, drips, or reducing valves. Several items, such as supports, insulation, and some valves and fittings, are the same for steam and hot-water distribution.
Gravity hot-water distribution systems operate because of the gravitational pull on the heavier cool water, which sinks as the heated water becomes lighter and rises. At this point, some of the types of gravity systems that are currently used are discussed.
One-Pipe, Open-Tank System
Figure 4-63.—A one-pipe, open-tank gravity hot-water distribution system.
The one-pipe, open-tank gravity distribution system shown in figure 4-63 consists of a single distribution pipe that carries the hot water to all of the convectors or radiators and returns it to the boiler. This system is easy to install and moderate in cost.
The water that flows into the radiators at the end of the system has a lower temperature than the water entering the first radiators. A system of this type should be designed so the water reaching the last convector is not too much cooler than the water reaching the first drop in the distribution system, convector radiators should be installed at the end of the system to equalize the amount of heat radiation per radiator. It is difficult to get enough circulation by gravity to give the system small convector temperature drops; consequently, we do not recommend the one-pipe, open-tank gravity system.
Two-Pipe, Open-Tank System
Figure 4-64.—A two-pipe, open-tank gravity hot-water
Many hot-water gravity distribution systems are two-pipe, open-tank systems, as shown in figure 4-64. This heating system is constructed with separate water mains for supplying hot water and returning cold water. The radiators are connected in parallel between the two mains. In the two-pipe, open-tank gravity system, the distributing supply mains are either in the basement with upfeed to the radiators or in the attic. When the system is in the attic, it has overhead downfeed supply risers. The return mains are in the basement. Return connections for the two-pipe system are usually made into a gravity return, which pitches downward to the return opening in the heating boiler. The water temperature is practically the same in all radiators, except for the allowance to be made for the temperature drop in the distribution supply mains occurring between the boiler and the end of the circuit. Water temperatures are the lowest at the end of the circuit. The amount of temperature drop between the beginning and the end of the line depends upon the length of the main and upon the heating load.
A tank with its vent open to the atmosphere is installed in the system above the highest radiator for water expansion. The water level in the expansion tank rises and falls, as the system is heated and cooled, and the system is full of water and free from air at all times. In the open-tank gravity hot-water heating system, the expansion tank is installed on a riser directly above the boiler, so the air liberated from the boiler water enters the tank and is not retained in the system.
One-Pipe, Closed-Tank System
A one-pipe, closed-tank gravity hot-water distribution system, as shown in tigure 4-65, is similar to the one-pipe, open-tank gravity hot-water heating system, except the expansion tank is a pneumatic compression tank not open to the atmosphere. When the water in a closed-tank system is heated, it. expands into the pneumatic compression tank. This action permits system operation at a much higher water temperature, without boiling, than the temperature in the one-pipe, open-tank gravity system. This also results in higher heat emission from the radiators.
Figure 4-65.—.A typical one-pipe, closed-tank distribution system.
A gravity open-tank system with an average boiler water temperature of 170°F has a radiator emission rate of 150 Btu psi, whereas a gravity closed-tank system with an average boiler water temperature of 190°F has a radiator emission of 180 Btu per square foot (psf). Higher boiler water temperatures permit higher temperature drops through the radiators; consequently, smaller pipe sizes can be used. The closed pneumatic compression system requires a relief valve, usually set for the relief of water pressure over 30 psi, depending upon the height of the building. A pressure-regulating valve automatically maintains the system full of water. Installation of the radiators and piping for an equivalent two-pipe, closed-tank gravity upfeed or overhead downfeed system is the same as that for the open system, except the sizes of both the pipe and the radiators are uniform and can be smaller. The open-tank system may have a reversed return main that does not go directly back to the boiler.
It doubles back from the last radiator and parallels the supply main back to the boiler entrance. The reversed return system allows equal length of heating circuits for al I radiators. Friction and temperature losses for all radiators are nearly equal. In most cases, the reversed return system involves no more piping than other piping arrangements. With the correct size of piping and radiator supply tappings, the reversed return system provides even heat and circulation to all radiators, even those near the end of the circuit.
Expansion in a Gravity Hot-Water Distribution System
In the gravity and forced-circulation systems, open and closed expansion tanks allow the water in the distribution system to expand as the temperature rises. An open tank must be mounted at the highest point in the system; a closed tank can be located at any point. If the air cushion leaks out of the closed expansion tank, it fills with water. At times, you must recharge the tank by draining part of the water out of the tank and allowing air to -fill the space.
In the open system, an expansion tank open to the atmosphere allows the system to expand. The open system is normally designed to operate at the maximum boiler temperature of 180°F. This gives an average radiator temperature of 170°F or a radiator output of 150 Btu psf. The closed system, in which the expansion takes place against a cushion of air in the tank closed against the atmosphere, can be operated at temperatures above 2 12°F because the pressure built up in the system prevents the water from boiling. Radiator temperatures then become equal to those of low-pressure steam systems.
When a hot-water system is first filled with water, it is normally necessary to bleed the air out of the system at the same time. You can remove the air by opening an air vent on a radiator or by breaking a union near the end of the line. The temperature of the water distributed is from 150°F to 250°F. The higher temperatures are used with the forced-circulation systems.
Forced-circulation hot-water distribution systems have several advantages. They permit the use of smaller pipe sizes and allow the installation of radiators at the same level as the boiler, or below, without impairing water circulation. By using a circulation pump, a positive flow of water is assured throughout the system. In larger installations, especially where more than one building is served, forced circulation is almost invariably used. With the development of a circulation pump of moderate cost, the forced-circulation system is being used more in small heating installations.
Even as in gravity systems, forced-circulation systems can consist of a one-pipe or a two-pipe, upfeed or downfeed, and can be equipped with a direct or a reversed return. Although these systems usually have closed expansion tanks, they may have open tanks.
One-Pipe, Closed-Tank System
The general arrangement of a one-pipe, closed-tank, forced-circulation system shown in figure 4-66 is similar to the one-pipe gravity system, but with the addition of a circulating pump.
Figure 4-66.—A one-pipe, closed-tank distribution system with a circulating pump.
The circulation to individual radiators is improved by special supply and return connecting tees. These tees, by an ejecting action on the distribution supply main and an ejecting action on the return, combine to use a portion of the velocity head in the main to increase circulation through the radiators. Tees of this type also aid stratification of hot and cold water within the distributing main. They are designed to take off the hot-test water from the top of the main and to deposit the colder water on the bottom of the main.
Two-Pipe, Closed-Tank System
The general arrangement of the piping and radiators for the two-pipe, forced-circulation distribution system is the same as that for the two-pipe gravity system. The relative locations of the compression tank relief valve and the circulating pump are shown in figure 4-67.
Figure 4-67.—A two-pipe, closed-tank, forced-circulation system.
DISTRIBUTION SYSTEM COMPONENTS
The component parts of a hot-water distribution system are similar to that of steam heating systems as described in chapter 3. They include the following: pipelines, radiators, convectors, unit heaters, circulating pumps, reducing valves, flow-control valves, and special flow fittings.
The piping system constitutes the closed passageway for the delivery of hot water to the points where it is used. Pipelines are made of lengths of pipe fastened by screwed, flanged, or welded joints. They have valves and fittings, such as tees, unions, and elbows, according to the needs of the installation. Pipelines are supported by hangers and fastened by anchors. Expansion joints or loops allow for expansion.
Mains and branches of the pipeline should be pitched so the air in the system can be discharged through open expansion tanks, radiators, and relief valves. The pitch is generally not less than 1 inch for every 10 feet. The piping arrangements for a new system should provide for draining the entire system.
The radiator transfers heat from the hot water in the pipes of a hot-water heating system into the surrounding air in a room. A radiator is usually of two types. Cast-iron radiators are constructed and assembled in sections, as shown in figure 4-68, view A. Damaged radiator sections can be replaced without replacing the entire radiator assembly. Fin-tube radiators (fig. 4-68, view B) are constructed of steel pipe and fins, which are welded to the pipe.
Radiators usually rest on the floor. However, they can be either mounted on a wall or hung from the ceiling. The location of a radiator depends on the type of room to be heated and its location with respect to the location of the boiler. For instance, in a forced-circulation hot-water distribution system, the radiators may be on the same level with the boiler.
A. Cast iron; B. Fin tube; C. Convector.
Convectors are supported on the wall much in the same way as a pipe. The convectors consist of a fin-tube radiator mounted in a metal cabinet and transfer heat much in the same way, although a damaged section must be welded or the entire convector must be replaced (fig. 4-68, view C).
Hot-water heating system radiators and high points in the distribution lines must have some type of vent that releases air from the system. Air trapped in the system prevents the circulation of water. For this purpose, a manually operated key-type air vent, as shown in figure 4-69, can be used.
Figure 4-69.—A manually operated key-type air vent.
Manually operated key-type air vents can be replaced by automatic air vents. One type of automatic air vent is shown in figure 4-70. It automatically allows the air that forms in the system to escape. When air vents fail, replace them.
Radiators also have shutoff valves, as shown in figure 4-71, which reduce or stop the flow of hot water through a radiator. They are installed in the piping next to the inlet side of the radiator. Occasionally, you must tighten the packing nut on these valves to prevent the water from leaking around the valve stem.
Figure 4-70.—One type of automatic air vent.
Figure 4-71.—A typical radiator shutoff valve.
Unit heaters are the same as those used in warm-air heating, except hot water is used vice coils for the heating medium. The heater consists of a heating coil supplied with hot water. The coil is usually of the finned type, and an electric fan circulates air over it. A unit heater installed in a distribution main is shown in figure 4-72.
Figure 4-72.—A typical hot-water unit heater installation.
Servicing unit heaters includes a monthly inspection. Each month, check for water leaks, cleanliness of the finned coils, and the operation of the fan motor. Other accessories which you also should inspect are traps, air vents, fan blades, and valves. Make any needed repairs. Lubricate the electric fan monthly.
A forced hot-water heating system has a water-circulating pump in the return line near the boiler. This pump ensures the positive flow of water regardless of the height of the system or the drop in the water temperature. Greater velocities of water flow are obtainable with forced circulation than with gravity circulation.
Circulating pumps are free of valves and float control elements. They are operated under a sufficiently high water inlet temperature to eliminate the difficulties caused by vapor binding. The pumps are usually operated by electric motors.
During maintenance servicing, check the pump carefully for proper rotation, and lubricate the electric motor and pump according to the manufacturer's instructions. Also, periodically clean the pump of sand, rust, and other foreign matter that has collected in the pump casing. Be sure the pump rotates freely and the shaft packing glands, if there are any, are not drawn up so tight that they score the shaft.
A reducing valve is normally installed in the cold-water line going to the boiler. It automatically keeps the closed system supplied with water at a predetermined safe system pressure. These valves are usually set at the factory, but you may adjust them in the shop to a desired pressure. You should install this valve at approximately the same level as the top of the boiler.
Forced hot-water circulating systems use the flow-control valve shown in figure 4-73. It is normally installed in the distribution main. This valve prevents gravitational flow of water through the system. The valve does not offer any serious resistance to the flow of water when the circulating pump is in operation. However, when the pump is not operating, the small gravitational head of water cannot open the valve. Each week you should check the flow-control valve for proper operational down-free movement. Examine the valve for water leaks and repair it when necessary.
Figure 4-73.—One type of flow-control valve.
Special Flow Fittings
Various types of special tees designed to deflect main-line water into the radiator branches are used in one-pipe and two-pipe forced-circulation systems. These fittings are designed and calibrated to the size of the radiator and system-operating temperature. Fittings of this type are required with one-pipe, forced-flow systems, and they do equally well for radiators above and below the distribution mains.
MAINTAINING AND TROUBLESHOOTING HOT-WATER HEATING SYSTEMS
Hot-water heating systems require little maintenance other than periodic checks to make certain that all air is out of the system and all radiators are full of water. The circulating pumps should be oiled regularly according to the manufacturer's instructions, and the pressure-relief valves should be checked periodically.
Operator maintenance on the electrically driven feed pump consists mostly of cleaning the pump and motor. However, the pump motor is lubricated according to the manufacturer's specifications. Remember that not using enough lubricant can result in the bearings running dry or seizing on the motor shaft. But, too much lubricant causes the motor to become dirty, and it can result in the motor windings becoming saturated with oil and burning out.
When a water leak develops around the pump shaft, tighten the packing-gland nuts or repack the stuffing box as necessary. The strainer, installed between the pump and the condensate receiver, should be kept clean to avoid any restriction of the flow of water to the pump.
The maintenance of feed-water heaters and economizers normally includes removing solid matter that accumulates in the unit; stopping steam and water leaks; and repairing inoperative traps, floats, valves, pumps, and other such associated equipment.
Questions for Lesson 6
- What is the main reason to install a two-pipe, open tank, gravity distribution system over a one-pipe, open-tank, gravity distribution system?
- The operations of what component of the one-pipe, closed-tank distribution system results in higher heat emission from the radiators?
- Air vents release trapped air in the system. If the air is not released, how would this affect the system?